System and method for securing flexible foam mattress covers from misalignment

ABSTRACT

A mattress covering system and associated method including a flexible foam mattress core having a top surface, a bottom surface and side walls connecting the top and bottom surfaces, a mattress cover made of a flexible and stretchable material, and a fabric connector mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.

This application claims the benefit and priority of U.S. Provisional Application No. 61/241,890, filed on Sep. 12, 2009, and U.S. Provisional Application No. 61/241,892, filed on Sep. 12, 2009, each of which is herein incorporated by reference in its entirety for all purposes.

BACKGROUND

1. Field

The disclosure relates to mattresses, and more specifically to a system and method for securing mattress covers to flexible foam mattresses to avoid misalignment.

2. Related Art

One measure frequently addressed by flexible foam mattress manufacturers that strive to comply with “Green” manufacturing criteria, involves the desire to create an improved carbon footprint by creating transportation fuel savings that result when a product is compression packaged. It is possible that flexible foam mattresses can be compressed to occupy less than half the normal uncompressed space (potentially up to ⅕th the uncompressed space) but such compression packaging has a negative impact on the product integrity due to damage of the covering fabrics.

Damage created by “over compressing” might be evident immediately when the packages are opened or they may linger and impact the product's performance over time. Frequently, where the flexible foam is a compressible material that will not be harmed by such compression, it is the covering fabric that is affected.

Many mattresses are constructed with zippered covers, which are soft but not necessarily highly flexible or stretchy in order to maintain a degree of fit and tailoring under normal use conditions. However, these zippered closure covers tend to become misaligned during compression packaging and frequently wrapped and stressed as never intended. Particularly, the use of roll-up machines introduces arrant force vectors that cause these problems.

It is common that flexible foam mattresses are closed using exterior cloth covers made from rigid fabrics that are used with zippers. The zipper is a construction closure technique that allows for the removal of mattress cover for laundering. It is true for all zippered closed mattresses where the cover is also removable that the cover cannot be connected to the mattress core. Typically, zippered covers rely on the tightness of the fit to the foam mattress core and fabric with very little stretch to facilitate alignment with the core. Too much stretch in a zippered cover makes it difficult to achieve a tight fitting cover.

Typically, zippered covers, using non-stretch fabric covers tend to become ill fitting and misaligned either from prolonged use or from the effects of compression packaging. The initial appearance and tailoring of mattresses generally connotes quality and in addition, misaligned covers can affect the mattress comfort and sleep performance.

SUMMARY

The present disclosure provides a fabric connector used to prevent the misalignment of a mattress cover due to the stress and misalignment inputs created by recovery from various compression-packaging techniques, and which may occur during the continuous use of the mattress. The system and associated method described helps to insure that the look and tailoring of the flexible foam mattress created during manufacturing remains intact during the useful life of the foam mattress. The present disclosure uses of fabric connectors coupled to the interior foam elements of any flexible foam mattress core to connect the cover to the core. Fabric connectors may be gathered up in the process of closing the mattress. Using a tape-edge closing technique along the base edge sewn closure of the mattress, the mattress cover is ensured a proper fit and tailoring against misalignment.

In one aspect, a mattress covering system is provided including a flexible foam mattress core having a top surface, a bottom surface and sidewalls connecting the top and bottom surfaces, and a mattress cover made of a flexible and stretchable material. The system also includes a fabric connector mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.

In another aspect, a mattress covering system is provided including a flexible foam mattress core having one to a plurality of support layers, a top surface, a bottom surface and side walls connecting the top and bottom surfaces. The system also includes a mattress cover made of a flexible and stretchable material. The mattress cover has a top cover that is disposed over the top surface of the flexible foam mattress core and over the sidewalls, where the top cover is coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress. A fabric connector is mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core. A mattress closure is coupled to the top cover of the mattress cover, to the bottom cover of the mattress cover and to the fabric connector to bring the top cover, the bottom cover and the fabric connector together in a sewn closure.

In yet another aspect, a method is provided for securing a mattress cover to a foam mattress including providing a flexible foam mattress core including one to a plurality of support layers, the flexible foam mattress having a top surface, a bottom surface and side walls connecting the top and bottom surfaces; mounting a fabric connector to at least a portion of the flexible foam core; enveloping the flexible foam mattress in a mattress cover made of a flexible and stretchable material, the mattress cover having a top cover which is disposed over the top surface of the flexible foam mattress core and over the side walls, and the top cover being coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress; and coupling the fabric connector to the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.

A more complete understanding of the invention can be obtained by reference to the following detailed description of the embodiments thereof in connection with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:

FIG. 1 is a simplified illustration of a mattress having a form fitting cover thereon;

FIG. 2 is a simplified illustration of a fabric connector mounted to the mattress core in accordance with an embodiment of the present invention;

FIG. 3 is a simplified illustration of a fabric connector mounted to the mattress core in accordance with an embodiment of the present invention; and

FIG. 4 is a simplified illustration of the fabric connector being used in the tape edge closing technique in accordance with an embodiment of the present invention;

FIG. 5 is a perspective view of a compressed and rolled mattress;

FIG. 6 is a perspective view of a bagged compressed and rolled mattress; and

FIG. 7 is an illustration of a flexible, stretchy fabric covering in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

FIG. 1 is a simplified illustration of a mattress core 100, such as a flexible foam mattress core having one to a plurality of support layers. The core 100 is part of a foam mattress core covering system. The system also includes a mattress cover 102 made of a flexible and stretchable material. In one embodiment, the cover 102 may include a stretchy top cover 104, which is disposed over a top surface 106 of the core 100 and over the sidewalls 108 thereof. The top cover 104 is coupled to a bottom cover 110 disposed over the bottom surface 112 of core 100. The cover may be made of any suitable stretchy material.

As shown in FIG. 2, a fabric connector 202 is mounted to the core 100 to be coupled to the cover 102 as part of the mattress covering system to alleviate the possibility of misalignment during compression packing or extended use of the mattress. In one embodiment, the fabric connector 202 may be a single sheet of fabric secured to the bottom surface 112 or top surface 106 of core 100, which extends out over an edge of the core 100 for securing to the mattress cover 102. In other embodiments, the fabric connector 202 may be a single sheet of fabric that extends along the perimeter of the core 100 coupled to the side walls 108 and extending out over an edge of the core 100 for securing to the mattress cover 102.

In still other embodiments, the fabric connector 202 may not be a single sheet of fabric, but a plurality of tabs or sheet segments secured on a bottom surface 112, a top surface 106 or the side walls 108 of the core 100 and extending out over an edge of the core 100 for securing to the mattress cover 102.

As shown in FIG. 3, in mattress cores 100 having a multiple layers, such as layers 302 and 304, fabric connectors 202, in either sheet form or tab form may be captured between the layers and allowed to extend out therefrom for securing to the mattress cover 102.

As shown in FIG. 4, in one exemplary embodiment, a tape edge mattress closing technique is used to couple the top cover 104 to the bottom cover 110 involving the fabric connector 202. In the exemplary embodiment, the tape edge mattress closing technique involves the gathering up of the fabric connector 202, a side surface of the top cover 104 and the bottom cover 110 and bringing these fabrics together in a sewn closure edge 402. Simultaneously, covering the sewn closure edge 402 with a separate piece of fabric tape 404 introduced both for appearance and construction integrity. It should be understood that the fabric connector 202 in each of its embodiments, for example, coupled to any surface on the core 100 or inserted between the layers of a multilayer core, is suited for use in the tape edge technique. It should be further understood that the fabric connector 202 may be a single sheet fabric or sheet segment or tabs as in the embodiments described above, and be suitable for use with the taped edge technique. The tape edge technique is a well known technique for securing fabric edges together and is commonly used in the construction of innerspring mattresses. The sewn closures may be performed using, for example, Kevlar thread, so as to not interfere with the flame test performance of the mattress.

In operation, the fabric connector 202 is mounted and secured to the mattress core 100 either by gluing or some other equivalent means. The fabric connector is then fastened to the cover 102, using the tape edge technique or some other equivalent means to attach the fabric connector to the cover 102. Thus, by positioning and securing the fabric connector 202 to the cover 102, the cover 102 is held in place around the core 100 to avoid the misalignment of the cover.

The present disclosure provides for the use of highly elastic covering materials to insure that stresses present during the severe compression packaging of the flexible foam mattresses do not translate to damage of the fabric covers. The unique mattress design and silhouette are the result of this functional effort.

The benefit of the highly elastic covering is an immediate recovery from compression packaging after opening and a quick recovery of the covering fabric to produce a smart fit and tailored look without any lasting stress related damage to the cover fabric. This solution also optimizes the physical capabilities and takes advantage of the full tape edge to tape edge attachment for the cover to create beneficial maximum flexibility across the whole top surface of the flexible mattress core.

Once fully opened and in service, the fabric covering works elastically across the full surface, from tape edge to tape edge closure, to allow surface compliance in the range of values that are consistent with flexible foam mattresses.

FIG. 5 is a perspective view of a compressed and rolled foam mattress 500. The rolled mattress 500 may be bagged and shipped as shown in FIG. 6. Rolled compression foam mattresses packaging is accomplished by machinery that imparts stress into the product and its covering fabric, such as covering fabric 502, that are generally inconsistent and uneven. Thus, of particular concern is the ability of the covering fabric 502 to be able to be pulled and stressed and held under severe pressures without exceeding the fabric's performance capabilities.

In one embodiment, the flexible foam mattress core construction is multi-layered and glued, a construction that can withstand the rolled compression packaging technique. However, typically mattress covers do not possess the ability to stretch and recover to the extent necessary to be pulled and stressed and held under severe pressures and not be damaged or appear to be damaged. Thus, in accordance with an embodiment, a covering fabric 502 with a high elastic performance, such as shown in FIG. 7, may be used in place of more stiff, launderable and/or zippered covers. In one embodiment, the elastic performance may be greater than 135% of more typical mattress covers.

Generally, mattress covers do not possess such a high degree of stretchability since the stretchability makes it harder to keep the cover from becoming misaligned. However, in accordance with an embodiment, the highly elastic performing covering fabric 502 may be attached to the fabric connectors 202 (FIGS. 2-4) as described above to ensure that the elastic covering fabric 502 is not misaligned or damaged due to the rolled compression packaging.

In one example, with no intent to be limiting, the covering fabric 502 may be a composite of a combination of Spandex up to about 2%, a fibrous material up to about 40%, such as bamboo and the like and polyester up to about 60%.

While the present invention has been shown and described with reference to specific embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. 

1. A mattress covering system comprising: a flexible foam mattress core, having a top surface, a bottom surface and side walls connecting the top and bottom surfaces; a mattress cover made of a flexible and stretchable material; and a fabric connector mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.
 2. The mattress covering system of claim 1, wherein the flexible foam mattress core comprises one to a plurality of support layers.
 3. The mattress covering system of claim 1, wherein the mattress cover comprises a top cover which is disposed over the top surface of the flexible foam mattress core and over the side walls, wherein the top cover of the mattress cover is coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress.
 4. The mattress covering system of claim 1, wherein the fabric connector comprises a single sheet of fabric secured to the bottom surface or top surface of the flexible foam mattress core.
 5. The mattress covering system of claim 1, wherein the fabric connector comprises a fabric connector that extends out over an edge of the flexible mattress core.
 6. The mattress covering system of claim 1, wherein the fabric connector comprises a single sheet of fabric that extends along the perimeter of the flexible mattress core coupled to the side walls and extending out over an edge of the flexible mattress core.
 7. The mattress covering system of claim 1, wherein the fabric connector comprises a plurality of tabs or sheet segments secured on the bottom surface, the top surface or the sidewalls of the flexible mattress core.
 8. The mattress covering system of claim 1, wherein the flexible mattress core comprises multiple layers and wherein at least a portion of the fabric connector is captured between adjacent layers.
 9. The mattress covering system of claim 1, further comprising a mattress closure to couple a top cover of the mattress cover to a bottom cover of the mattress cover and to the fabric connector.
 10. The mattress covering system of claim 9, wherein the mattress closure is made using a tape edge mattress closing technique comprising the gathering up of the fabric connector, with the top cover of the mattress cover and the bottom cover of the mattress cover and bringing them together in a sewn closure.
 11. A mattress covering system comprising: a flexible foam mattress core including one to a plurality of support layers, the flexible foam mattress having a top surface, a bottom surface and side walls connecting the top and bottom surfaces; a mattress cover made of a flexible and stretchable material, the mattress cover having a top cover which is disposed over the top surface of the flexible foam mattress core and over the side walls, and the top cover being coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress; a fabric connector mounted to the flexible foam core and coupled to at least a portion of the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core; and a mattress closure coupled to the top cover of the mattress cover, to the bottom cover of the mattress cover and to the fabric connector to bring the top cover, the bottom cover and the fabric connector together in a sewn closure.
 12. The mattress covering system of claim 11, wherein the fabric connector comprises a single sheet of fabric mounted to the bottom surface or top surface of the flexible foam mattress core.
 13. The mattress covering system of claim 11, wherein the fabric connector comprises a fabric connector that extends out over an edge of the flexible mattress core.
 14. The mattress covering system of claim 11, wherein the fabric connector comprises a single sheet of fabric that extends along the perimeter of the flexible mattress core coupled to the sidewalls.
 15. The mattress covering system of claim 11, wherein the fabric connector comprises a plurality of tabs or sheet segments mounted on the bottom surface, the top surface or the sidewalls of the flexible mattress core.
 16. The mattress covering system of claim 11, wherein at least a portion of the fabric connector is captured between adjacent layers of the flexible foam core.
 17. A method for securing a mattress cover to a foam mattress comprising: providing a flexible foam mattress core including one to a plurality of support layers, the flexible foam mattress having a top surface, a bottom surface and side walls connecting the top and bottom surfaces; mounting a fabric connector to at least a portion of the flexible foam core; enveloping the flexible foam mattress in a mattress cover made of a flexible and stretchable material, the mattress cover having a top cover which is disposed over the top surface of the flexible foam mattress core and over the side walls, and the top cover being coupled to a bottom cover of the mattress cover disposed over the bottom surface of the flexible foam mattress; and coupling the fabric connector to the mattress cover to alleviate the possibility of misalignment during compression packing or extended use of the flexible foam mattress core.
 18. The method of claim 18, wherein mounting the fabric connector to at least a portion of the flexible foam core comprises mounting a single sheet of fabric secured to the bottom surface or top surface of the flexible foam mattress core.
 19. The method of claim 18, wherein mounting the fabric connector to at least a portion of the flexible foam core comprises mounting a single sheet of fabric that extends along the perimeter of the flexible mattress core coupled to the side walls and extending out over an edge of the flexible mattress core.
 20. The method of claim 18, wherein mounting the fabric connector to at least a portion of the flexible foam core comprises mounting a plurality of tabs or sheet segments to the bottom surface, the top surface or the sidewalls of the flexible mattress core. 